Synthetic resins and preparation thereof



Fatenteei Fete. 20, 195i;

SYNTHETIC RESEN S AND PREPARATION THEREOF Herman S. Bloch, Chicago, Ill., assigncr to Universal Oil Products Company, Chicago, 111., a

corporation of Delaware No Drawing. Application September 28, 1948, Serial No.51,641

16 Claims.

This application is a continuation-impart of my copending application Serial Number 611,792, now Patent No. 2,453,298, Nov. 9, 1948, filed August 20, 1945, as a continuation-in-part of ap plication Serial Number 500,425, filed August 28, 1943, now abandoned.

This application relates to the preparation of resinssuitable for use as coating compositions.

An object of this invention is the preparation of a resin by interaction of an alkylbenzcne hydrocarbon, a phenol, and a dihaloalkane in the presence of a Friedel-Crafts metal halide catalyst, hydrolysis of the reaction mixture and condensation of a carbonyl compound with said hydrolysis product.

Another object of this invention is the preparation of a resin by reacting an alkylbenzene having not more than two alkyl substituents, a monohydric phenol, and a dichloride of a normally gaseous olefin in the presence of a 'Friedel- Crafts metal chloride catalyst, hydrolyzing the reaction product, and reacting the hydrolysis product with an aldehyde or ketone to form a resin.

In one embodiment, this invention relates to a process for producing a resin which comprises reacting in the presence of a Friedel-Crafts metal halide catalyst: (1) an alkylbenzene hydrocarbon having not more than two alkyl groups per molecule and each of said alkyl groups having not more than two carbon atoms per group, 2) a phenolic compound selected from the group consisting of monohydric phenols, dihydrio phenols, and the methyl, ethyl, and prenyl ethers of said phenols, said phenolic compounds containing not more than two nuclearly substituted alkyl groups per molecule as the sole nuclear substituents and each of said alkyl groups having not more than two carbon atoms per group, and (3) a dihaloalkane having from two to four, inclusive, carbon atoms per molecule and a halo gen atom of at least 35 atomic weight bound to each of two adjacent carbon atoms; the amount of catalysts being at least 5 mole per cent more than (2), the amount of 1) being at least mole percent of the total of 1) (2) and (3) the molar amount of (2) being from about one-tenth to about one-half of the total of (1) and (2), and the amount of (3) being from about 1 to about 20 moles per mole of total (1) and (2) terminating the reaction when from about 1.0 to about 1.5 moles of hydrogen halide have been evolved per mole of total aromatic compounds reacted, hydrolyzing the resultant reaction prodnot to form a mixture of an aqueous layer and organic material comprising aromatic hydrocarbon-phenolic compound-dihaloalkane reaction product, reacting said mixture with a carbonyl compound selected from the group consisting of aldehydes and ketones at a temperature of from about to about C., and recovering the,

hydrocarbons. When employed in coating compositions, the resins produced from phenols, alkylbenzene hydrocarbons, dihaloalkanes and formaldehyde or another carbonyl compound adhere well to metals and various woods and are more satisfactory and durable than the purely hydrocarbon resins.

The resins formed by my process diifer markedly from those prepared previously by condensing an alkali metal or alkaline earth metal phenolate of a polyhydric phenol with an organic polyhalide whose halogen atoms are attached to aliphatic carbon atoms. In this prior art method, the alkali or alkaline earth metal of the phenolate of the mentioned polyhydric phenol combined with the halogen of the organic polyhalide and thus formed a metal halide and effected a condensation of the polyhydric phenol, with the carbon chain of the organic polyhalide forming an organic condensation product of resinous nature. Such a condensation product contains ether linkages formed by a reaction mechanism of the type:

In my process, an alkylbenzene hydrocarbon, a and/or ethyl groups. Typical phenol ethers thus monohydric' or dihydric phenol, and a dihaloinclude anisole, phenetole, diphenyl ether, etc. alkane are interacted in the absence of an alka- The alkylene dihalides preferred for use in my line condensing agent but in the presence of a process are produced by addition of a halogen to Friedel-Craits metal halide catalyst to form a a gaseous monooleilnic hydrocarbon and particureaction product and a hydrogen halide, the larly to ethylene. These dihaloalkane contain latter being evolved from the process. Accord- 2, 3, and 4 carbon atoms per molecule and have ingly, my process yields an intermediate product a halogen atom of at least atomic weight containing free hydroxyl groups and in which bound to each of two adjacent carbon atoms.

the aromatic reactants are linked to the alkylene Although dichloro-, dibromo-, and diiodo-alkanes carbon atom chain by nuclear bonds as indiare useful in my process, I prefer to utilize the cated in the equation: dichloroalkanes because of their cheapness and on n n I H H T T 11 H T no e-ar Eifi-o-c-i'di'iiic c-Ei! eig-c-c-z'c'i'ai-c on a H n "g n n l n cn H\/E n cn o o o E H E on n I g a n H E 110/ c-- J c c- -g-p on 111'; on Hp; tr! Hg en f f f o c c n n n A reaction product of the alkylbenzene hydroavailability. Other suitable dihaloalkanes are carbon, phenolic compound and dihaloalkane is produced by the halogenation of parafflnic, cyclothen hydrolyzed and the resultant hydrolysis 3n paraffinic and cycloolefinic hydrocarbons. mixture containing acidic material is reacted The use of dihaloalkanes containingfrom 2 to further with a carbonyl compound selected from 4, inclusive, carbon atoms per molecule results in the group consisting of ketones and aldehydes. the production of hard resins, while softer resins preferably formaldehyde. with softening points below about 65 C. and

The aromatic hydrocarbons employed in my more tarry products are formedfrom dihaloprocess are alkylbenzene hydrocarbons having alkanes of higher molecular weights. not more than two alkyl groups and not more The charging stock of my process for producthan two carbon atoms in each of said alkyl ing resins should contain at least 10 mole per groups. These alkylbenzene hydrocarbons incent of the mentioned alkylbenzene hydrocarclude toluene, the xylenes, monoethylbenzene, w bons, while the amount of phenolic material presand the diethylbenzenes. The aromatic hydroent should be from about one-tenth to about carbons used in this process may be either the one-half of the total molar amount of aromatic pure alkylbenzene hydrocarbons or may comprise compounds, that is, alkylbenzene hydrocarbons a substantially olefin-free hydrocarbon fraction plus phenols, present in the mixture. The precontaining these aromatic hydrocarbons in adferred amount of dihaloalkane present in the ren ixture with paraifinic and naphthenic hydroaction mixture also is about 2 to about 5 moles carbons. Suitable saturated hydrocarbon iracof dihaloalkane per mole of total alkyl aromatic tions containing alkylbenzene hydrocarbons may hydrocarbons and phenols if pure alkyl aromatic be of naphtha or gasoline boiling range, or of hydrocarbons and phenols are utilized rather kerosene boiling range. If the alkyl substituents than hydrocarbon fractions containing these macontain more than two carbon atoms, dealkylaterials; but molar ratios of alkylene dihalide to tion occurs, and the olefins formed thereby unaromatic compounds as low as slightly above 1 dergo conjunct polymerization with the formato about 20 may be used. However, it a naphtha tion of undesirable by-products. fraction is used, it is preferable to employ the The phenolic compounds which are reacted dihaloalkane in suflicient excess so that after with the other resin-forming substances as here- 65 the condensation reaction is completed, the molar in set forth comprise phenols and phenol ethers ratio of the unconsumed dihaloalkane to the total having per molecule not more than two oxygen of the parafiinic and naphthenic hydrocarbons atoms and not more than two nuclearly substipresent in the reaction mixture is greater than 2. tuted alkyl groups, each of said allwl groups con- Catalysts employed in my process comprise the taining not more than two carbon atoms. The metal halides of the Friedel-Craits type and inmonohydric phenols include particularly phenol, elude particularly aluminum chloride, aluminum cresols, xylenols, and naphthols, and their methyl bromide, ferric chloride, ferric bromide, etc. In and ethyl homologues having not more than two addition to the metal halide catalysts, boron nuclear alkyl substituents. Resorcinol, catechol, fluoride is also suitable. In general, the amount hydroquinone, and other dihydric phenols and of catalyst employed is from about 5 to about their methyl and ethyl substituted homologues 15 mole per cent more than the amount of phehaving not more than two alkyl groups are dihynolic compound charged to the reaction mixture. dric phenols which are useful in my process. In the presence of these catalysts, the conden- Other phenolic compounds utilizable in my procsation reaction is carried out at a temperature of as for producing resins comprise methyl aryl from about 25 to about 200 C. and preferably ethers and ethyl aryl ethers producible from at a temperature of from about-50 to about phenols as well as diaryl ethers wherein the aryl C. While the condensation occurs at atmosgroup is a phenyl group'or a phenyl group subpheric pressure, it is sometimes advantageous to atltuted by an alkyl group having not more than effect the condensation at a superatmospheric two carbon atoms and thus including methyl 7; pressure. The reaction is preferably carried out bers as acetone, methylethylketone, diethylketone, etc., cyclic saturated ketones such as methylcyclohexylketone, cyclic members wherein the carbonyl group is part of the ring. such as cyclohexanone, unsaturated ketones, such is vinylmethylketone, ethylidene-acetone, mesityl oxide, phorone, etc., aryl ketones such as acetophenone, butyrophenone, benzophenone, etc., and alkenyl arylketones such as propenylphenylketone and homologs of the above classes. Typical aldehydes include such compounds as formaldehyde, acetaldehyde, crotonaldehyde, benzaldehyde, cinnamaldehyde, and others.

In carrying out the process of the present invention, a mixture of an aromatic hydrocarbon or a hydrocarbon fraction containing aromatics and a phenolic compound is commingled with a molar excess of a dihaloalkane, also referred to as an alkylene dihalide, and is heated inthe presence of a Friedel-Crafts metal halide catalyst, preferably aluminum chloride, until the evolution of hydrogen chloride bears a ratio of about 1.5 moles per mole of total aromatic compound employed, the total aromatic compound including both alkylbenzene hydrocarbons and phenolic compounds. The reaction mixture is then-subjected tov hydrolysis and the hydrolysis product is reacted further with an aldehyde or ketone such as formaldehyde. When formaldehyde is used, it is added in a molar amount approximately equal to that of the phenol charged to the process. The formaldehyde is then condensed with the phenolaromatic hydrocarbon-alkylene dihalide reaction product in the presence of the acid-hydrolyzing medium which serves as the condensation catalyst. Any excess formaldehyde and alkylene dihalide present are removed by steam distillation and the resultant resinous material is dried.

Alternatively, the excess alkylene dihalide such as ethylene dichloride, may be removed by steam distillation before addition of the formaldehyde. It is convenient, however, to have it present as a solvent for the primary resinoid as the latter is then maintained in a more fluid state and is capable of more uniform reaction with the formaldehyde.

It is sometimes preferable to add the phenolic material to the reaction mixture after partial condensation has been effected between the arcmatic hydrocarbon and the polyhaloalkane. Although less catalyst is needed when following this method of procedure, great-er care is required to insure a homogeneous product having satisfactory properties.

The following examples illustrate my invention but should not be considered as limiting the broad scope of the invention in accordance therewith.

Example I To an equimolecular mixture of 100 grams of xylene and phenol was added 247 grams of ethylene chloride and 84 grams of aluminum chloride.

The reactants were heated at a temperature which varied from 60 to 92 C. until 1.46 mole of hydrogen chloride were evolved. After hydrolysis of the mixture, 0.5 mole of formaldehyde was reacted at 82 C. with the product from the first step. The resin formed was found to have a ball and ring softening point of 102 C. and was slightly soluble in organic solvents. After baking at 110 C., it became extremely hard and tough.

Example II A mixture comprising 3 moles of xylene to one of phenol was combined with ethylene dichloride and reacted in the presence of aluminum chloride. The reaction temperature was 60 C. After 1.32 moles of hydrogen chloride per mole of total aromatics had been evolved, the product was subjected to hydrolysis and reacted with formaldehyde at C., the molar ratio of formaldehyde to phenol being 1 to 1. A solid, hard, homogeneous resin was obtained which also had a softening point of 102 C. by the ball and ring method.

Example III The initial resinoid was made as in Example II, but the reaction was stopped after 1.20 moles of hydrogen chloride per mole of aromatics had been liberated. After hydrolysis of the reaction mixture, the excess ethylene dichloride was removed by steam distillation. The residue was then washed several times with water, then drained free of superficial water, and finally dried at 130 C. The soft plastic mass was kneaded with slightly over 2 moles of formaldehyde per mole of phenol present (the formaldehyde being added as powdered solid paraformaldehyde) and the mixture was heated 8 hours at -l10 C. Approximately one-third of the formaldehyde was recovered. The resinous product was a clear, homogeneous solid, softening at 65 C. (ball and ring) and soluble in glyceride dryin oils, aromatic hydrocarbons and butyl acetate.

Example IV A mixture of 0.5 mole of xylenes, 0.5 moleof anisole, and 2.5 moles of ethylene dichloride was heated to 60 C. and anhydrous aluminum chloride gradually in portions of approximately 0.16 mole each. No hydrogen chlorde was evolved during the addition of the first three portions, which covered a period of one hour and forty minutes during which the temperature was raised from 60 to C. Upon the addition of the fourth portion of catalyst (to make a total of 0.63 mole), a rapid evolution of hydrogen chloride began. The reaction was continued for 3.5 hours longer at temperatures varying between 70 and 95 C., during which 1.5 moles of hydrogen chloride was evolved. The reaction mixture was then cooled, decomposed with water, and steam-distilled. From an analysis of the steam distillate, it was determined that all of the xylenes and anisole had reacted, and that 1.09 moles of ethylene dichloride had been consumed. The resinous product was a yellowish, mediumhard solid of ball and ring softening point 96 C., relatively insoluble in mineral spirits and acetone, moderately soluble in carbon disulfide, Cellosolve, and linseed oil. and readily soluble in tolutZita, benzene, carbon tetrachloride and butyl ace- This product, when dissolved in toluene and refluxed with 1.1 moles of aqueous 35 weight per cent Formalin for two hours in the presence of five per cent of sulfuric acid, was raised in softenof said phenols, said phenolic having ing point to 130 C. with relatively little change in its solubility characteristics.

I claim as my invention:

1. A process for producinga resin which comprises reacting in the presence of a Friedel-Crafts metal halide catalyst: (1) an alkylbenzene hydrocarbon having not more than two alkyl groups per molecule and each of said alkyl groups having not more than two carbon atoms per group, (2) a phenolic compound selected from the group consisting of monohydric phenols, dihydric phenols, and the methyl, ethyl, and phenyl ethers taming not more than two nuclearly substituted allwl groups per molecule as the sole nuclear substltuents and each of said alkyl groups having not more than two carbon atoms per group, and

(3) a dihaloalkane having from two to four. in-

clusive, carbon atoms per molecule and a halogen atom of at least 35 atomic weight bound to each of two adjacent carbon atoms; the amount of catalyst being at least'5 mole per cent more than (2), the amount of (1) being at least mole percent of the total of (1) (2) and (3), the molar amount of (2) being from about onetenth to about one-half of the total of (1) and v (2), and the amount of (3) being from about 1 to about moles per mole of total (1) and (2) terminating the, reaction when from about 1.0

- to about 1.5 moles of hydrogen halide have been evolved per mole of. total aromatic compounds reacted, hydrolyzing the resultant reaction product to form a mixture of an aqueous layer and organic material comprising aromatic hydrocarbon-phenolic compound-dihaloalkane reaction product, reacting said mixture with a carbonyl compound selected from the group consisting of aldehydes and ketones at'a temperature of from about 60 to about 150 C., and recovering the resultant organic condensation product.

2. A process for producing a resin which comprises reacting in the presence of a Friedel-Crafts metal halide catalyst at a temperature of from about C. to about 200 C.: (1) an alkylbenzene hydrocarbon having not more than two alkyl groups per molecule and each of said alkyl groups having not morethan two' carbon atoms per group, (2) a phenolic compound selected from the group consisting of monohydric phenols, dihydric phenols, and the methyl, ethyl, and phenyl ethers of said phenols, said phenolic compounds containing not more than two nuclearly substituted alkyl groups per molecule as the sole nuclear substituents and each of said alkyl groups not more than two carbon atoms per group, and (3) a dihaloalkane having from two to four, inclusive, carbon atoms bound to each of two adjacent carbon atoms; the amount of catalyst being at least 5 mole per cent more than (2), the amount of (1) being at least 10 mole per cent of the total of (1) (2) and (3), the molar amount of (2) being from about onetenth to about one-half of the total of (1) and (2), and the amount of (3) being from about 1 to about 20 moles per mole of total (1) and (2) terminating the reaction when from about 1.0 to about 1.5 moles of hydrogen halide have been evolved per mole of total aromatic compounds reacted, hydrolyzing the resulting reaction product to form a mixture of an aqueous layer and organic material comprising aromatic hydrocarbon-phenolic compound-'dihaloalkale reaction product, reacting said mixture with a carbonyl compound selected from the group consisting of.

compounds conper molecule and a halogen atom of at least atomic Weight aldehydes and ketones at a temperature of from about 60 to about 150 0., and recovering the resultant organic condensation product.

3. A process for producmg a resin which comprises reacting in the presence of a Friedel-Crafts metal halide catalyst at a temperature of from about 50 C. to-about 0.: (1) an alkylbenqzene hydrocarbon having not more than two alkyl groups per molecule and each of said alkyl groups having not mor than two carbon atoms per group, (2) a phenolic compound selected from the group consisting of monohydric phenols, dihydric phenols, and the methyl, ethyl, and phenyl ethers of said phenols, said phenolic compounds containing not more than two nuclearly substituted alkyl groups per molecule as the sole nuclear substituents and. each of said alkyl groups having not more than two carbon atoms per group, and (3) a dihaloalkane having from two to four, inclusive, carbon atoms per molecule and a halogen atom or at' least 35 atomic weight bound to each of two adjacent carbon atoms; the amount of catalyst being at least 5 mole per cent more than (2), the amount of (1) being at least 10 mole per cent of the total of (1) (2),

and (3), the molar amount or (2) being from about one-tenth to about one-half of the total of *(1) and (2), and the amount or (3) being from about 1 to about 20 moles per mole of total (1)- and (2) terminating the reaction when from about 1.0 to about 1.5 moles of hydrogen halide have been evolved per mole of total aromatic compounds reacted, hydrolyzing the resultant reaction product to form a mixture of an aqueous layer and organic material comprising aromatic hydrocarbon-phenolic compound-dihaloalkane reaction product, reacting said mixture with a carbonyl compound selected from thegroup consisting of aldehydes and ketones at a temperature of from about 60 to about C., and recoverzng the resultant organic condensation product.

4. The process defined in claim 1 further characterized in that the amount of'dihaloalkane is from about two to about five moles per mole of total alkylbenzene hydrocarbon and:v phenolic compound. I

5. The process defined in claim 1 further c'haracterized in that said catalyst comprises aluminum chloride. I

6. The process defined in claim l iurther characterized in that said dihaloalkane comprises a dichloroalkane.

l. The process defined in claim 1 further characterized in that said phenolic compound comprises a monohydric phenol.

8. The process defined in claim 1 further characterized in that said alkylbenzene comprises Xylene.

9. The process defined in claim 1 iurther characterized in that said dihaloalkane comprises ethylene dichloride.

10. The process defined in claim 1 further characterized in that said carbonyl compound comprises an aldehyde.

11. The process defined in claim 1 further characterized in that said carbonyl compound comprises formaldehyde.

12. A process for producing a resin which comprises reacting xylene, phenol, and ethylene dichloride in the presence of aluminum chloride at a temperature of from about 50 C. to about 100 C., the amount of aluminum chloride beingat least 5 mole per cent more than the molar N amount of phenol, the molar amount or said xylene being at least 10% of the total reactants, the molar amount of said phenol being from about 0.1 to about 0.5 of the total aromatic reactants, and the amount of said ethylene dichloride being from above one to about 20 moles per mole of total aromatic reactants; termihating the reaction when from about 1.0 to about 1.5 moles of hydrogen chloride have been evolved per mole of total aromatic reactants; hydrolyzing the resultant reaction product to form a mixture of an acidic aqueous layer and organic material comprising xylene-phenol-ethylene dichloride reaction product; reacting said mixture with a molar amount of formaldehyde approximately equal to that of the charged phenol, at a temperature of from about 60 to about 150 C. to form a resinous condensationproduct; and recovering said condensation product.

13. A process for producing a resin which comprises reacting xylene, anisole, and ethylene dichloride in the presence of aluminum chloride at a temperature of from about 50 to about 100 0.; the amount of aluminum chloride being at least mole per cent more than the molar amount of anisole, the molar amount of said xylene being at least of the total reactants, the molar amount of said anisole being from about 0.1 to about 0.5 of the total aromatic reactants, and the amount of said ethylene dichloride being from above one to about twenty moles per mole of total aromatic reactants; terminating the reaction when from about 1.0 to about 1.5 moles of hydrogen chloride have been evolved per mole of total aromatic reactants; hydrolyzing the resultant reaction product to form a mixture of an acidic aqueous layer and organic material comprising xylene-anisole-ethylene dichloride reaction product, reacting said mixture with a molar amount of formaldehyde approximately equal to that of the charged anisole, at a temperature of from about to about C. to form a resinous condensation product; and recovering said condensation product.

14. The resin produced according to the process of claim 1.

15. The resin produced according to the process of claim 12.

' 16. The resin produced according to the process of claim 13. I

HERMAN S. BLOCH.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,416,218 Reifi Feb. 18, 1947 2,453,298 Bloch Nov. 9, 1948 

1. A PROCESS FOR PRODUCING A RESIN WHICH COMPRISES REACTING IN THE PRESENCE OF A FRIEDEL-CRAFTS METAL HALIDE CATALYST: (1) AN ALKYLBENZENE HYDROCARBON HAVING NOT MORE THAN TWO ALKYL GROUPS PER MOLECULE AND EACH OF SAID ALKYL GROUPS HAVING NOT MORE THAN TWO CARBON ATOMS PER GROUP, (2) A PHENOLIC COMPOUND SELECTED FROM THE GROUP CONSISTING OF MONOHYDRIC PHENOLS, DIHYDRIC PHENOLS, AND THE METHYL, ETHYL, AND PHENYL ETHERS OF SAID PHENOLS, SAID PHENOLIC COMPOUNDS CONTAINING NOT MORE THAN TWO NUCLEARLY SUBSTITUTED ALKYL GROUPS PER MOLECULE AS THE SOLE NUCLEAR SUBSTITUENTS AND EACH OF SAID ALKYL GROUPS HAVING NOT MORE THAN TWO CARBON ATOMS PER GROUP, AND (3) A DIHALOALKANE HAVING FROM TWO TO FOUR, AND CLUSIVE, CARBON ATOMS PER MOLECULE AND A HALOGEN ATOM OF AT LEAST 35 ATOMIC WEIGHT BOUND TO EACH OF TWO ADJACENT CARBON ATOMS; THE AMOUNT OF CATALYST BEING AT LEAST 5 MOLE PER CENT MORE THAN (2), THE AMOUNT OF (1) BEING AT LEAST 10 MOLE PERCENT OF THE TOTAL OF (1), (2), AND (3), THE MOLAR AMOUNT OF (2) BEING FROM ABOUT ONETENTH TO ABOUT ONE-HALF OF THE TOTAL OF (1) AND (2), AND THE AMOUNT OF (3) BEING FROM ABOUT 1 TO ABOUT 20 MOLES PER MOLE OF TOTAL (1) AND (2), TERMINATING THE REACTION WHEN FROM ABOUT 1.0 TO ABOUT 1.5 MOLES OF HYDROGEN HALIDE HAVE BEEN EVOLVED PER MOLE OF TOTAL AROMATIC COMPOUNDS REACTED, HYDROLYZING THE RESULTANT REACTION PRODUCT TO FORM A MIXTURE OF AN AQUEOUS LAYER AND ORGANIC MATERIAL COMPRISING AROMATIC HYDROCARBON-PHENOLIC COMPOUND-DIHALOALKANE REACTION PRODUCT, REACTING SAID MIXTURE WITH A CARBONYL COMPOUND SELECTED FROM THE GROUP CONSISTING OF ALDEHYDES AND KETONES AT A TEMPERATURE OF FROM ABOUT 60* TO ABOUT 150* C., AND RECOVERING THE RESULTANT ORGANIC CONDENSATION PRODUCT. 